Triton Traction Service Manual Domestic DTS Model

SERVICE MANUAL

Traction Unit

Applies to Serial numbers 1000 and above

International Model- 4749

International with sEMG Model- 4798

Domestic Model- 4739

Domestic with sEMG Model- 4778

Domestic DTS Model- 2841

© 2006 Encore Medical, L.P.

ISO 13485 Certifi ed

TABLE OF CONTENTS

Triton® Traction Unit

FOREWORD . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 1

1 THEORY OF OPERATION .. .. .. .. .. .. .. .. .. .. .. .. .. .. 2

1.1 OVERVIEW .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..2

2 SAFETY PRECAUTIONS .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 3

3 NOMENCLATURE . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..67

4 SPECIFICATIONS .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 8

4.1 PHYSICAL SPECIFICATIONS . .. .. .. .. .. .. .. .. .. ..8

5 TROUBLESHOOTING . .. .. .. .. .. .. .. .. .. .. .. .. .. .. 929

5.2 TRITON TRACTION UNIT TESTING . .. .. .. .. .. 14

REMOVAL & REPLACEMENT . .. .. .. .. .. .. .. 41-46

REMOVAL & REPLACEMENT .. .. .. .. .. .. 47-48

REMOVAL & REPLACEMENT .. .. .. .. .. .. .. .. 49


6.13 MOTOR ASSEMBLY




7 CALIBRATION.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 56

7.1 UNIT CALIBRATION.. .. .. .. .. .. .. .. .. .. .. .. .. 56-58

8 PARTS . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 61

5.6 ON/OFF SWITCH TEST .. .. .. .. .. .. .. .. .. .. .. .. .. 16

5.7 ON/OFF SWITCH TROUBLESHOOTING . .. .. 16

8.2 SIDE COVERS . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 62

5.9 CORD RELEASE AND RETRACT TEST .. .. .. .. 18

5.10 CORD RELEASE TROUBLESHOOTING . 19-20

8.4 BASE AND EXTRUSION ASSEMBLY .. .. .. .. .. 64

AND POWER SUPPLY.. .. .. .. .. .. .. .. .. .. .. .. .. .. 66

6 REMOVAL & REPLACEMENT .. .. .. .. .. .. .. .. .. 3055

6.1 SIDE COVER REMOVAL & REPLACEMENT .. 30

6.2 TOP AND CORD GUIDE COVER

REMOVAL & REPLACEMENT . .. .. .. .. .. .. .. .. .. 31



6.5 MOTOR CONTROL BOARD




6.8 CLAMP SPRING ASSEMBLY


SPOOL ASSEMBLY . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 68

9 SCHEMATICS .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 6979

9.1 TRITON TRACTION UNIT SCHEMATICS . 69-79

CONTROL BOARD .. .. .. .. .. .. .. .. .. .. .. .. .. .. 70-72

MOTOR CONTROL BOARD.. .. .. .. .. .. .. .. .. 73-74

PATIENT INTERRUPT SWITCH .. .. .. .. .. .. .. .. .. 75

SERIAL INTERFACE . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 76

SMART CARD.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 77

sEMG BOARD.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 78

BLOCK DIAGRAM .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 79

10- SPECIAL FIXTURES .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 80-83

CALIBRATION FIXTURE .. .. .. .. .. .. .. .. .. .. .. .. .. 80-83

11 WARRANTY .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 84

FOREWORD


Read, understand, and follow the Safety Precautions and all other information contained in this manual.

This manual contains the necessary safety and field service information for those field service technicians, certified by Chattanooga Group, to perform field service on the Triton unit.

At the time of publication, the information contained herein was current and up-to-date. However, due to continual technological improvements and increased clinical knowledge in the field of traction therapy, as well as Chattanooga Group’s policy of continual improvement, Chattanooga

Group reserves the right to make periodic changes and improvements to their equipment and documentation without any obligation on the part of Chattanooga Group.

It is the sole responsibility for certified field technicians to stay informed and trained in the latest technology utilized in the Triton units by Chattanooga Group. From time to time, as significant improvements are incorporated, service bulletins will be produced and made available on our web site (chattgroup.com) in lieu of reprinting a complete manual prematurely. These service bulletins will provide updated service information and technological improvements to the Triton unit for use by certified service technicians.

Due to the complex nature of the technology utilized by Chattanooga Group, the recommended troubleshooting techniques are to determine “Bad Board” and board replacement only. No board component level troubleshooting is recommended, nor will information or parts be supplied by

Chattanooga Group.

Any board component level troubleshooting performed will be at the sole risk and liability of the certified field service technician performing such troubleshooting techniques. Performance of such techniques may render the warranty null and void.

Triton® are prescription devices to be used only under the supervision of and by the order of a physician or other licensed health care provider.

©2006 Encore Medical Corporation or its affiliates, Austin, Texas, USA. Any use of editorial, pictorial, or layout composition of this publication without express written consent from the Chattanooga Group of Encore Medical, L.P. is strictly prohibited. This publication was written, illustrated, and prepared for print by the Chattanooga Group of

Encore Medical, L.P.

1

1 THEORY OF OPERATION


1.1 OVERVIEW

The Triton traction unit is comprised of several pieces of proprietary hardware and software causing the unit to function as required allowing administration of traction therapy under the prescription and supervision of a licensed medical practitioner.

The Touch Screen Assembly houses the necessary hardware and software to communicate to the Motor

Control Board. Communicates commands and limits as established by the user through use of the Touch

Screen. The Touch Screen Assembly, in conjunction with the Motor Control Board, monitors the functionality of the entire system during the course of the traction therapy being administered. Should the unit malfunction or a communication error occur, the unit will stop treatment and generate an error message to notify the operator of a possible problem.

The Touch Screen Assembly communicates to the Motor Control Board Assembly via a proprietary bus.

The Motor Control Board communicates to the Touch Screen Assembly throughout the therapy session all parameters via feedback from the Motor Assembly and the Load Cell Assembly.

The Touch Screen Assembly incorporates a Patient Data Card Reader/Writer for the purpose of storing Patient

Treatment Data that can then be downloaded to a PC equipped with the optional PDMS System.

2

2 SAFETY PRECAUTIONS

2.1 PRECAUTIONARY DEFINITIONS

The precautionary instructions found in this section and throughout this manual are indicated by specific symbols. Understand these symbols and their definitions before operating this equipment. The definition of these symbols are as follows:

A. Caution

Text with a “CAUTION” indicator will explain possible safety infractions that could have the potential to cause minor to moderate injury or damage to equipment.

2.2 PRECAUTIONARY INSTRUCTIONS

A. Cautions

B. Warning

Text with a “WARNING” indicator will explain possible safety infractions that will potentially cause serious injury and equipment damage.

C. Danger

Text with a “DANGER” indicator will explain possible safety infractions that are imminently hazardous situations that would result in death or serious injury.

D. Dangerous Voltage

Text with a “Dangerous Voltage” indicator serves to inform the technician of possible hazards resulting in the electrical charge disbursement from certain components if handled or serviced improperly.

E. NOTE

Throughout this manual, “NOTE” may be found.

These Notes are helpful information to aid in the particular area or function being described.


•

Read, understand, and practice all precautionary instructions found in this manual. Know the limitations and hazards associated with using any electrical traction device. Observe the precautionary and operational decals placed on the unit.

•

Do not use accessories other than those supplied with the unit or recommended by Chattanooga

Group. The safety of other products has not been established, and their use could result in injury to the patient.

•

This unit should be transported and stored in temperatures between 0°F and 140°F (-18°C and 60°C) to prevent damage to the unit or its components.

•

DO NOT operate this unit in an environment where other devices are being used that intentionally radiates electromagnetic energy in an unshielded manner. Portable and mobile RF communications equipment can affect Medical

Electrical Equipment.

•

This unit generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to other devices in the vicinity. However, there is no guarantee that interference will not occur in a particular installation. Harmful interference to other devices can be determined by turning this (table, unit, device, etc.) on and off. Try to correct the interference using one or more of the following: reorient or relocate the receiving device, increase the separation between the equipment, connect the equipment to an outlet on a different circuit from that which the other device(s) are connected and consult the Chattanooga Group

Service Department for help.

•

The unit should be routinely checked before each use to determine all controls function normally.

•

Handle the unit with care. Inappropriate handling of the unit may adversely affect its characteristics.

•

Before each use, inspect the Traction Cord for wear. Prolonged wear on the cord will cause it to break, which may cause sudden release of traction pressure on a patient.

•

Test the Patient Interrupt Switch before each use for power operation.

3


2.2 PRECAUTIONARY INSTRUCTIONS (continued)

B. Warnings


•

Do not remove the cover. This may cause unit damage, malfunction, electrical shock, fire, or personal injury. There are no user-serviceable parts inside the unit. If a malfunction occurs, discontinue use immediately, disconnect the Mains Power Cord from the outlet, and consult the dealer for repair service.

•

Do not use sharp objects such as a pencil point or ballpoint pen to operate the buttons on the LCD base as damage may result.

•

Do not permit any foreign materials or liquids to enter the unit. Take care to prevent any foreign materials including, but not limited to, inflammables, water, and metallic objects from entering the unit. These may cause unit damage, malfunction, electrical shock, fire, or personal injury.

•

Do not disassemble, modify, or remodel the unit or accessories. This may cause unit damage, malfunction, electrical shock, fire, or personal injury.

•

Do not use the traction unit near devices such as

X-ray units or diathermy units. These units may emit high frequency noise that may affect the operation of the unit.

•

Failure to use and maintain the traction unit and its accessories in accordance with the instructions outlined in this manual will render the warranty void.

•

In the event of a loss of power to the unit or when quick release is needed, traction tension should only be released by having the patient move towards the traction head to release the tension on the rope. Once the tension on the rope has been released, loosen the patient harness adjustment straps.

•

The tool, lubrication, and locking compound requirements listed are critical to component removal and replacement of the unit.

•

The hardware, bolts, nuts, and screws used to assemble the Triton are SAE and Metric. Therefore, it will be necessary to obtain both SAE and Metric tools for removal and replacement of components.

•

The lubricant and locking compound listed are crucial in the assembly of certain components to ensure patient safety and efficient operation of the unit.

•

Use of controls or adjustments or performance of procedures other than those specified herein may result in a hazardous traction related injury.

•

Before connecting the unit to an electrical outlet, make certain the unit is electrically grounded by connecting only to a grounded electrical service receptacle conforming to the applicable national and local electrical codes.

•

Do not use a damaged Mains Power Cord. Using a damaged Mains Power Cord may cause unit damage, malfunction, electrical shock, fire, or personal injury. If the Mains Power Cord becomes damaged, discontinue use immediately and contact the dealer for replacement of the Mains Power Cord.

•

This device should be kept out of the reach of children.

•

Always hand tighten the Lock Knob securely to avoid any slippage.

•

Care must be taken when operating this unit, adjacent to or stacked with other equipment.

Potential electromagnetic or other interference could occur to this or other equipment. Try to minimize this interference by not using other equipment in conjunction with it.

•

In the event of a loss of power to the unit, traction tension should only be released by gradually lengthening the patient harness adjustment straps.

•

Dispose of all products in accordance with local and national regulations and codes.

•

In the event that an Error message or Warning appears beginning with a 2 or 3, immediately stop all use of the system and contact the dealer or

Chattanooga Group for service. Errors and Warnings in these categories indicate an internal problem with the unit that must be tested by Chattanooga

Group or a Field Service Technician certified by

Chattanooga Group before any further operation or use of the unit. Use of a unit that indicates an Error or Warning in these categories may pose a risk of injury to the patient, user, or may cause extensive internal damage to the unit.

•

Unit failing Dielectric Withstand and/or Leakage

Tests could indicate serious internal problems.

DO NOT place the back into service! Send unit to factory for repair! DO NOT attempt to repair the unit in the field!

•

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

•

When performing Unit Calibration Procedure, the

Calibration Fixture Load Cell must be set to US lbs.

4


2.2 PRECAUTIONARY INSTRUCTIONS (continued)

C. Dangers

•

Use only accessories that are specially designed for this unit. Do not use accessories manufactured by other companies on this (table, unit, device, etc.). Chattanooga Group is not responsible for any consequence resulting from using products manufactured by other companies. The use of other accessories or cables may result in increased emissions or decreased immunity of this (table, unit, device, etc.).

•

This component removal and replacement procedure requires that the following be performed after component or assembly replacement to ensure proper alignment and operation of the unit:

COMPLETE CALIBRATION OF UNIT

Refer to Section 7

AND

MINIMUM OF 2 HOUR BURN IN OF UNIT AFTER

SUCCESSFUL CALIBRATION Refer to Section 7

Failure to perform either of these procedures, after

a component or assembly replacement will void

warranty and may result in injury to patients

and/or severe equipment damage.

• It is not recommend tying a new knot in a cord that has frayed or failed in use or is worn in an area from constant use. The cord must be replaced.


• DO NOT connect the unit to an electrical supply without first verifying that the power supply is the correct voltage.

Incorrect voltage may cause unit damage, malfunction, electrical shock, fire, or personal injury. Your unit was constructed to operate only on the electrical voltage specified on the Voltage Rating and Serial

Number Plate. Contact the Chattanooga

Group dealer if the unit is not properly rated.

• Power Supplies retain High Voltage!

• Discharge the C4 Capacitor prior to complete removal of the Power Supply.

• Discharge the C4 Capacitor prior to handling of the new Power Supply.

• Triton® is a prescription device to be used only under the supervision of and by the order of a physician or other licensed health care provider.

• Do not use any other knot styles in the

Cord other than those specified in this manual. Use of other knot styles could cause Cord to completely disengage from the system and may cause serious injury to patient and personnel.

5

3 NOMENCLATURE

3.1 TRITON UNIT EXTERNAL COMPONENTS

The nomenclature graphics below, Figure 3.1, indicate the general locations of the major external components of the Triton traction unit.

1


Know the components and their functions before performing any operation of or service to the

Triton traction unit.

2

3

7

6

4

5

1.

2.

3.

4.

5.

Touch Screen Assembly

Top and Cord Guide Cover

Traction Cord Knuckle

Front Cover

Patient Interrupt Switch Receptacle

10

9

FIGURE 3.1

6.

7.

8.

Side Cover

Clamp Assembly Knob

Rear Cover

9.

Mains Power Cord Receptacle

10.

On/Off Power Switch

6

8

3 NOMENCLATURE

3.2 INTERNAL COMPONENTS

The nomenclature graphics below, Figure 3.2, indicate the locations of the major internal components of the Triton traction unit.

9


Know the components and their functions before performing any operation of or service to the

Triton traction unit.

1

2

3

4

5

8

7

10

6

12

11

4.

5.

6.

1.

2.

3.

Chassis

Load Cell

Top Front Traction Cord Guide

Traction Cord

Front Cover Mounting Bracket

Motor Control Board

FIGURE 3.2

7.

8.

9.

Motor Assembly

Power Supply

Cord Tension Spring and Housing

10.

Clamp Spring Assembly

11.

Large Driven Gear

12.

Solenoid Assembly

7

4 SPECIFICATIONS

4.1 PHYSICAL SPECIFICATIONS


HEIGHT

DEPTH

WIDTH

FIGURE 4.1

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 cm (9.5 in)

Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 cm (17.5 in)

Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 cm (17.5 in)

Weight

Standard Weight . . . . . . . . . . . . . . . . . . . . . . . .14 kg (30 lbs)

Shipping Weight . . . . . . . . . . . . . . . . . . . . . . . .18 kg (40 lbs)

Power

Voltage. . . . . . . . . . . . . . . . . . . . . . . . 100 V-240 V (50/60 Hz)

Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 VA

Current Consumption . . . . . . . . . . . . . . . . . . . . . . 3.2 A Max

Electrical Class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Class I

Traction Unit Electrical Type . . . . . . . . . . . . . . . . . .Type B sEMG Electrical Type . . . . . . . . . . . . . . . . . . . . . . Type BF

Traction Modes. . . . . . . . . . . . . . . . . Static, Intermittent,

Cyclic, and their combinations.

Traction Type . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical

LCD Display . . . . . . . . . . . . .High contrast monochrome

Touch Screen

Regulatory Compliance

Meets Directive 93 /42 /EEC

IEC/UL/EN: 60601-1 and 60601-1-2

CAN C22.2 No. 601.1-M90w/AZ

0 4 1 3

Traction Period

Hold Period

Rest Period

Traction Tension

Progrssive and

Regressive Steps

TRACTION TENSION SPECIFICATIONS

1 minute

0 seconds

0 seconds

0 kg (0 lb/0 N)

1 step

99 minutes

99 seconds

99 seconds

90 kg (200 lb/890 N)

9 steps

1 minute

1 second

1 second

1 kg (1 lb/5 N)

1 step

8

5 TROUBLESHOOTING

5.1 TRITON ERROR MESSAGES

A. The following information is provided

as an aid in defining the Software Error

Messages of the Triton traction unit.

Once a particular Error Message is defined,

the information will also list probable causes

and possible remedies. Once the problem

area is determined, subsequent tests for

verification will be necessary to determine

the subassembly or PC Board to be replaced.


In the case of PC Boards, all troubleshooting

and tests will be to validate a “Bad Board”

only. No component level troubleshooting

information is or will be provided by

Chattanooga Group for field troubleshooting

of PC board components.

B. Once a particular subassembly or PC Board

has been determined as bad, refer to the

appropriate Removal & Replacement

Section for the board affected and follow the

instructions for replacement of the board.

ERROR

CODE

100

101

102

104

105

106

107

112

113

114

108

109

110

111

115

ERROR

TYPE

DEFINITION PROBABLE CAUSES POSSIBLE REMEDY

USER CORRECTABLE WARNING MESSAGES

WARNING Treatment has been running for 8 seconds, but no tension is detected on the Cord.

WARNING Patient pressed Patient Switch.

WARNING Patient Switch is unplugged.

Too much slack in Traction Cord

Patient Interrupt Switch button pressed.

Patient Interrupt Switch not properly connected to unit.

Wrong or bad Patient Data Card inserted into unit.

Remove Traction Cord Slack.

Touch the Touch Screen to clear message.

Properly connect Patient Interrupt Switch and touch Touch

Screen to clear message.

Insert correct Patient Data Card.

WARNING User selected Patient Card button on utilities screen, but no traction treatments were found on the card.

No Patient Data Card inserted.

Properly insert correct Patient Data Card into unit.

WARNING User selected save to card, but no card is inserted into the unit.

WARNING User selected save to card, but the card currently inserted is not a Patient Card.

WARNING User selected save to card, but the card currently inserted is full.

WARNING User typed in a blank patient name.

WARNING User typed in a blank protocol name.

WARNING User attempted to access a MMC function, but no MMC is inserted into the unit.

WARNING User attempted to upgrade software, but the MMC in the unit is not a software upgrade MMC.

WARNING Error upgrading Control Board software.

WARNING Error upgrading motor board software.

WARNING User pressed START, but has not yet set the Max Level value to a value greater than zero.

WARNING User pressed HOME button from treatment review screen while a treatment was running.

Wrong or bad Patient Data Card inserted into unit.

Memory full on Patient Data Card used.

No Patient ID assigned.

No Protocol name entered.

No Multimedia Card (MMC) inserted into unit.

Wrong Multimedia Card (MMC) inserted into unit.

Unknown

Unknown

User has not completed Treatment Set Up.

Home button has been pressed.

Insert correct Patient Data Card.

Save Data to PDMS and erase Patient Data Card.

Enter Patient ID.

Enter Protocol name.

Insert Multimedia Card (MMC) into unit.

Insert proper Mutimedia Card (MMC).

Contact Dealer or Chattanooga Group for Service.

Contact Dealer or Chattanooga Group for Service.

Complete Treatment Set Up prior to pressing START.

Press STOP to end treatment prior to pressing HOME.

9


5.1 TRITON ERROR MESSAGES (continued)


In the event that an Error message or Warning appears beginning with a 2 or 3, immediately stop all use of the unit and contact the dealer or Chattanooga

Group for service. Errors and Warnings in these categories indicate an internal problem with the unit that must be tested by Chattanooga Group or a Field

Service Technician certified by Chattanooga Group before any further operation or use of the unit. Use of a unit that indicates an Error or Warning in these categories may pose a risk of injury to the patient, user, or may cause extensive internal damage to the unit.

ERROR

CODE

200

201

202

203

204

205

206

207

208

209

210

211

212

213

ERROR

TYPE


ERROR MESSAGES (200-223) REQUIRING TECHNICAL ASSISTANCE

ERROR The motor PCB has reset.

ERROR Error communicating with the realtime clock chip.

ERROR The motor PCB returned an error while performing the zero Load Cell function.

Motor Control Board is bad.

Control Board Communication Error.

Bad Load Cell Assembly

Motor Control Board Communication Error.

If the Error repeats routinely, replace Motor Control Board.

If the Error repeats routinely, replace Touch Screen Assembly.

ERROR Timeout waiting for the motor PCB to perform the zero Load Cell calibration.

ERROR Timeout waiting for the motor PCB to perform the motor current calibration.

Bad Load Cell

Bad Motor Control Board

Motor Control Board Communication Error.

1. Check Cables and Harnesses for proper seating and

connection on Motor Control Board.

2. Replace Load Cell Assembly.

3. Replace Motor Control Board.

4. Replace Touch Screen Assembly.

1. Ensure there is slack in the Cord.



3. Replace Load Cell.


1. Ensure there is no slack in the Cord.





ERROR A Motor fault error has occurred while a treatment was running.

ERROR We have detected a motor current error

(MC_MON pin on motor PCB).

Internal mechanical jam of unit.

Bad Motor Control Board or Motor Assembly.

ERROR The Motor PCB cannot get to the desired tension.

Internal Mechanical Jam of unit.

Bad Motor Control Board or Motor Assembly.

Unit out of calibration.

ERROR We have detected a Load Cell limit error

(LC_MON pin on motor PCB).

ERROR Error erasing a patient card.

Unit is out of calibration.

Bad Motor Control Board.

Bad Load Cell Assembly.

Bad Patient Data Card.

Bad Touch Screen Assembly.

ERROR CRC not correct on treatment just read from

Patient Card.

ERROR Error reading default protocol on power up so must rebuild protocols to factory presets.

Bad Patient Data Card.


EEPROM is corrupt.

ERROR The Motor PCB fl agged a comm watchdog error.

Touch Screen Assembly did not poll Motor Control

Board in a reasonable amount of time.

ERROR Motor PCB has indicated that the zero calibration value is invalid and needs to be calibrated.

Unit is out of calibration.

1. Correct any internal mechanical jam.

2. Replace bad Motor Control Board or bad Motor Assembly.

1. Correct any internal mechanical jam.

2. Replace bad Motor Control Board or bad Motor Assembly.

Perform Unit Calibration and Burn In procedures.

1. Perform Unit Calibration and Burn In procedures.


3. Replace Load Cell Assembly.

1. Try known good Patient Data Card.




1. Try known good Patient Data Card.


If the Error repeats routinely, replace Touch Screen Assembly.



2. If the Error repeats routinely, replace Touch Screen

Assembly.


10







ERROR

CODE

214

215

217

218

219

220

221

222

223

ERROR

TYPE


ERROR MESSAGES (200-223) REQUIRING TECHNICAL ASSISTANCE (continued)

ERROR User has confi gured a treatment such that it takes too much memory to compute the treatment steps. Unit will default back to the default power up protocol.

ERROR Internal error, unit cannot get the next treatment step information, treatment is terminated.

Under normal operating conditions, this Error should never appear.

Multimedia Card (MMC) Data is corrupt.

Multimedia Card (MMC) interface not working.

Remove unit from service and report exact treatment parameters to Chattanooga Group.

ERROR Error reading a MMC.

ERROR Error upgrading Control Board software.

Bad Mutimedia Card (MMC).

Improper cable connection to Motor Control Board.





1. Try known good Multimedia Card (MMC).

2. Remove unit from service and report exact treatment

parameters to Chattanooga Group.









ERROR Error upgrading Control Board software.

ERROR Error upgrading Motor Control Board software.





ERROR Error upgrading Motor Control Board software.





ERROR Patient switch is shorted.

ERROR Beta version evaluation period has expired.




Patient Interrupt Switch not completely seated in connector.

Bad Patient Interrupt Switch.

Bad Patient Interrupt Switch Connector.

Unit is designated BETA Test Unit.















1. Properly connect Patient Interrupt Switch to unit.

2. Use a known good Patient Interrupt Switch.

3. Replace Patient Interrupt Switch Connector on unit.

Immediately return unit to Chattanooga Group.

11







ERROR

CODE

300 through

307

308

309

310

311

312

313

314

ERROR

TYPE


CRITICAL

ERROR

CRITICAL

ERROR

CRITICAL

ERROR

CRITICAL

ERROR

CRITICAL

ERROR

CRITICAL

ERROR

CRITICAL

ERROR

CRITICAL

ERROR

CRITICAL ERRORS (300-314) DEMANDING TECHNICAL SERVICE

Communication Error between Touch Screen and Motor

Control Board.

We are supposed to be increasing tension, but tension is not increasing.

We are supposed to be decreasing tension, but tension is actually increasing.

Communication Error.

Slack in Cord.

Bad Load Cell.



Bad Harness connection.

Bad Load Cell.







1. Remove slack in Cord.











We are reading > 0 tension when we should be reading zero.

We are reading < 0 tension when we should be reading zero.

We have detected that the motor is running too fast.

Internal memory error.

Error reading EEPROM.


Bad Load Cell.



Bad Motor Assembly.

Bad Touch Screen.

Bad Touch Screen.







2. Replace Motor Assembly.

Replace Touch Screen Assembly.

Cycle power to unit. If the Error repeats, then replace

Touch Screen Assembly.

12

NOTES


13


5.2 TRITON TRACTION UNIT TESTING

A. General- Electronic

1. Information within this section in respect to

electronic components is intended to aid

in troubleshooting the PCB's of the Triton units

These tests are the standard testing

procedures and methods used at the factory

before shipment of the unit.

2. Due to the complex nature of the technology

utilized by Chattanooga Group, the

recommended PCB troubleshooting

techniques are to determine “Bad Board” and

board replacement only. No PCB

component level troubleshooting is

recommended nor will information or parts

be supplied by Chattanooga Group. Any PC

board component level troubleshooting

performed will be at the sole risk and liability

of the Service Technician performing such

3. Once a particular PCB has been

determined as bad, replace the PCB. Use

only Chattanooga Group replacement parts

B. General- Replacement Components

Critical component replacement parts for the

traction unit are available as subassemblies only.

This is due to the accuracy required and the

critical nature of the subassembly within the

unit for power function and operation. Individual

components of these subassemblies will not be

made available by Chattanooga Group.

C. General- Tests and Repair Procedures

1. Certain tests and repair procedures require the use of special tools and/or fixtures.

These will be listed at the particular test where they are required. Testing with any other special tool or fixture other than those stated could give erroneous readings or test results. Always perform the tests exactly as stated to ensure accurate results.

2. Test equipment settings will be listed for each test performed prior to the respective test to ensure the test is performed to

Chattanooga Group standards and ensure

3. The troubleshooting and repair of the units are to be performed only by authorized technicians trained and certified by


NOTE:

Adjust Dielectric Withstand tester to indicate fault with

120 kOhm load across the output when at specified test voltage.

2. Milliohm Meter

3. Digital Multimeter

4. Required Hand Tool

•

•

#1 Phillips Screwdriver


•

•

Flat Blade Screwdriver

• Calibrated Torque Wrench- 200 inch pound or 2,500 Newton meter minimum capacity.

Allen Wrenches

•

•

• SAE- 3/32, 5/32, and 9/64 in

Metric- 3 mm

Hex Key Sockets for Torque Wrench

The tool, lubrication, and locking compound requirements listed are critical to component removal and replacement of the unit.

The hardware, bolts, nuts, and screws used to assemble the Triton are SAE and Metric. Therefore, it will be necessary to obtain both SAE and Metric tools for removal and replacement of components.

The lubricant and locking compound listed are crucial in the assembly of certain components to ensure patient safety and efficient operation of the unit.

•

•

•

•

• SAE- 3/32 and 5/32 in

• Metric- 4 mm

Needle Nose Pliers

Tape Measure- 12 ft (3 meter) minimum

Ratchet

7mm Box End Wrench

• Pick for removing connector wires.

5. Touch Screen to Cover Assembly Jig

6. Calibration Fixture with calibrated Strain

Meter.

7. Solenoid Assembly Mounting Jig. P/N 48139.

8. Attenuator

9. Calibrated Audio Signal Generator, B-K

10. Test leads for Audio Generator to Attenuator.

D. Tools, Fixtures, and Equipment Required

1. Dielectric Withstand (Hi-Pot) and ground

resistance tester.

14


5.3 VISUAL INSPECTION

A. General

Visually inspect the unit. A visual

inspection can, to an experienced Technician,

indicate possible abuse of the unit and

5.4 GROUND RESISTANCE TEST

A. Voltage Specifications

Models 4759 and 4779 . . . . . . . . . Input: 100-240 VAC

50/60 Hz, 75 VA

B. Specification

Maximum Acceptable Resistance: 100 milliohms

C. Equipment Required

5.5 LEAKAGE TESTS


UNIT FAILING DIELECTRIC WITHSTAND AND/OR

LEAKAGE TESTS COULD INDICATE SERIOUS

INTERNAL SYSTEM PROBLEMS.

DO NOT PLACE UNIT BACK INTO SERVICE!

SEND UNIT TO FACTORY FOR REPAIR! DO NOT

ATTEMPT TO REPAIR IN THE FIELD!

Test Voltage Spec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1000 V

Conduct all necessary leakage tests as required per

“Chapter 7 Electrical Equipment” of the 1999, or later, edition of the NFPA (National Fire Protection

Association) “Health Care Facilities” standards.

See Figure 5.2.

D. Test

Place unit on level work surface.

Place one meter probe on the ground prong of

power supply and the other to any exposed

metal or screw on the unit. See Figure 5.1.

EXPOSED METAL

GROUND PRONG

FIGURE 5.1

NOTE:

U.S.A. Power Cord Illustrated.

Unit is illustrated on its side.

FIGURE 5.2

NOTE:

The NFPA "Health Care Facilities" standards are specific to the U.S.A. All other technicians should verify their country's requirements for these tests.

15


5.6 ON/OFF SWITCH TEST

A. Specification

Unit turns Off and On

B. Equipment Required

None

C. On/Off Switch Test Procedure

1. Place unit on level work surface.

2. Plug Power Cord into grounded power source

with appropriate voltage. See Specifications

3. Turn unit Off and back On with Power Switch.

D. Test Result

1. If unit turns Off and On, unit passed test.

2. If unit does not turn Off and On, unit failed

test. Refer to: 5.7 On/Off Switch

5.7 ON/OFF SWITCH TROUBLESHOOTING


Appropriate AC voltage.


Digital Multimeter

3/32 in Allen Wrench

C. On/Off Switch Troubleshooting Procedure

1. Disconnect unit from power source.Remove

Side Covers. Refer to 6.1 Side Cover Removal &

Replacement.

2. Remove Top Cover. Refer to 6.2 Top and Cord

Guide Cover Removal & Replacement.

3. Remove Rear Cover leaving harnesses

connected. Refer to 6.3 Rear Cover Removal

4. Disconnect the Blue and Red wires from the

Power Supply to the Power Switch. See

5. Set Multimeter to AC and to the appropriate

voltage setting. Connect Multimeter Leads

to the Blue and Brown wire Connectors from

the Power Switch. See Figure 5.5.

6. Plug unit into a grounded power source with

appropriate voltage. Turn Power Switch On

and take reading from Multimeter.

D. Test Result

1. If Multimeter reads appropriate voltage, unit

passed test. If unit will not power up, refer to

2. If Multimeter does not read appropriate

voltage.

ON/OFF

SWITCH

ON/OFF

SWITCH

FIGURE 5.3

DISCONNECT RED AND BLUE

POWER SUPPLY WIRES

FIGURE 5.4

MULTIMETER

CONNECTED TO BLUE

AND BROWN WIRES

FIGURE 5.5


16


5.8 PATIENT INTERRUPT SWITCH TEST


Unit displays Error 101 or 102 at the


None

C. Patient Interrupt Switch Test Procedure

1. Place unit on level work surface. Plug Power

Cord into grounded power source with

2. Connect Patient Interrupt Switch to unit

making certain it is completely seated in the

Patient Interrupt Switch connector. See

3. Turn unit On with Power Switch. After unit

has completely booted up, disconnect the

Patient Interrupt Switch. Unit should display

Error 102. See Figure 5.7.

4. Reconnect the Patient Interrupt Switch. Touch

the Touch Screen anywhere to clear the Error.

5. Turn unit Off. with Patient Interrupt Switch

connected to the unit, turn unit On with

6. After unit has completely booted up, depress

the Patient Interrupt Switch button. The unit

should display Error 101. Touch the Touch

Screen anywhere to clear the Error. See

D. Test Result

1. If unit displays Errors 101 or 102 at the

respective test, unit passed test.

2. If unit does not display Errors 101 or 102 at

the respective test, unit failed test. Repeat

test with a known good Patient Interrupt

Switch.

3. If known good Patient Interrupt Switch

resolves the problem, replace existing Patient

Interrupt Switch with new part.

4. If the known good Patient Interrupt Switch

does not remedy the problem, Replace

Patient Interrupt Switch Jack.

FIGURE 5.6

FIGURE 5.7


17

FIGURE 5.8


5.9 CORD RELEASE AND RETRACT TEST

A. Specification

Release . . . . . . . . . . . . . . . . . . . . Cord releases with less than 5 lbs tension

Retract . . . . . . . . . . . . . . . . . .Cord completely retracts


Calibration Fixture with calibrated Strain Meter.

C. Cord Release and Retract Test Procedures

1. Secure unit to the Calibration Fixture. See

5.9.

2. Plug unit into approved power source and

turn unit On.

3. After unit has completely booted, press and

hold Rope Release on Touch Screen, and

pull Cord out. Release Rope Release while

holding Cord out. See Figure 5.10.

NOTE:

It may be necessary to pull and release slight tension on the Cord to allow the internal mechanism to release the stop on the Cord.

4. While holding on to extended Cord, press

Rope Release on the Touch Screen and

guide Cord back into unit.

5. Repeat step 3 above to connect the Cord to

the Calibration Fixture. See Figure 5.11.

6. Set up unit for a static pull of 100 lbs. Refer

to User Manual if necessary.

7. Press the START button. After the 100 lbs has

been reached, press the STOP Button

and view the Rope Release on the Touch

Screen, it should be inactive.

8. Watch as the tension decreases. Once the

tension decreases to below 5 lbs, the Rope

Release should become active. Immediately

press the Rope Release on the Touch Screen,

pull enough Cord out to facilitate

disconnection from the Calibration Fixture.

Release the Rope Release control.

Disconnect the Cord from the Calibration

Fixture.

NOTE:

It may be necessary to apply and release slight tension on the Cord to allow the internal mechanism to release the stop on the Cord.

Repeat step 4.

D. Test Result

1. If Cord fails to release, unit failed test.

Refer to 5.10 Cord Release

Troubleshooting.

2. If Cord fails to completely retract, unit

failed test. Adjust Cord Retraction Spring.

Refer to page 42 beginning with step 13

for adjustment procedures.

18

FIGURE 5.9

FIGURE 5.10

FIGURE 5.11



5.10 CORD RELEASE TROUBLESHOOTING


Solenoid Gear . .Properly engages Driven Gear

Required


2. #1 Phillips Screwdriver

3. 3/32 in Allen Wrench

4. Solenoid Assembly Mounting Jig

C. Cord Release Troubleshooting Procedure

1. Solenoid Assembly

Cover Removal & Replacement.

b. Manually move solenoid shaft in and out

to ensure gears are not locked and the

Solenoid Shaft moves and properly

engages the large Driven Gear. See

Figure 5.12. If Solenoid moves and

engages properly, procede to step c. below.

If Solenoid Shaft will not move or

properly mesh with the Large Driven

Gear, adjust Solenoid Assembly. Refer

to page 46, parts A-D for adjustment. If

problem persists, replace Solenoid

Assembly. Refer to 6.11 Solenoid

Assembly Removal & Replacement procedures.

c. With unit connected to an approved

power supply and turned on, press the

Rope Release on the Touch Screen.

Repeat several times to ensure the

solenoid properly engages and

disengages the large Driven Gear.

1) Touch Screen Control does not activate

Solenoid. Troubleshoot Motor Control

Board. Refer to page 20 for instructions.

2) Solenoid Gear does not properly

engage the large Driven Gear. See

Figure 5.13. Adjust Solenoid

Assembly. Refer to page 46, parts A

through D for adjustment.

FIGURE 5.12

FIGURE 5.13


19


5.10 CORD RELEASE TROUBLESHOOTING (continued)

2. Motor Control Board

a. Disconnect Solenoid Harness from J8 on

Motor Control Board. See Figure 5.14.

b. Make certain unit is connected to an

approved power supply outlet and turn

unit On with Power Switch.

c.

connect leads to the J8 connector pins.

See Figure 5.15.

d. Push and hold the Rope Release on the

Touch Screen and take reading from

Multimeter.

1. If no voltage is present or low voltage

is present, replace Motor Control

Board. Refer to 6.5 Motor Control

Board Removal & Replacement.

2. If proper voltage is present and

problem persists, replace Touch

Screen Assembly. Refer to 6.6 Touch

Screen Removal & Replacement.

FIGURE 5.14


FIGURE 5.15

20


5.11 LOAD CELL TEST


Touch Screen Reading . . . . . . . . . . . . . . . . . . ±10%

Required

1. Calibration Fixture with calibrated Load Cell

C. Load Cell Test Procedure

2. Plug unit into an approved power source

and turn unit On with Power Switch.

3. After unit is completely booted, Press Cord

Release on the Touch Screen and pull out

enough Cord to connect Cord to

the Load Cell. See Figure 5.16.

4. After connecting Cord to Load Cell, allow

any slack Cord back into the unit. Release

the Rope Release on the Touch Screen.

5. Set up unit for a 100 lbs static pull. Refer to

User Manual if necessary.

6. Zero the Load Cell according to the

7. Press the START button just below the Touch

Screen. See Figure 5.17.

8. During the pull, compare and record the

reading on the Touch Screen to the reading

on the Load Cell at 25, 50, 75, and 100 lb intervals.

9. After 100 lbs has been reached, press the

STOP button. See Figure 5.18. Allow unit to

release the Cord.

D. Test Result

1. If reading of Load Cell is within ±10% of the

Touch Screen reading, unit passed test.

2. If readings are higher or lower than the

±10% tolerance, unit failed test. Calibrate

unit and re-test. Refer to Section 7

Calibration for Procedures.

3. If problem persists, perform Load

Cell Troubleshooting. Refer to 5.12 Load Cell

Troubleshooting for procedures.

FIGURE 5.16

FIGURE 5.17


21

FIGURE 5.18


5.12 LOAD CELL TROUBLESHOOTING


Voltage to Load Cell . . . . . . . . . . . . . . . . . .10 VDC

Voltage from Load Cell . . . . . . . . . . . . . . Variable

Motor Control Board Voltage (U3) . . . Variable

Required

1. Calibration Fixture with calibrated Load Cell



4. Pick for removing wires from connectors.

C. Voltage to Load Cell Test

Cover Removal & Replacement.

3. Plug unit into an approved power source and turn unit On with Power Switch.

4. After unit is completely booted, press Cord

Release on the Touch Screen and pull out enough Cord to connect Accessory Clip to the Load Cell. See Figure 5.19.

5. Guide any Cord slack back into unit.

Release the Rope Release on the Touch

Screen.

6. Remove Load Cell Connector from J11 on


7. Set Multimeter to read 10 VDC and connect leads to Pins 1 and 2 of the J11 connector on the Motor Control Board.

8. Multimeter should read 10 VDC.

If reading is 10 VDC, procede to step 9.

If reading is not 10 VDC, replace Motor

Control Board. Refer to 6.5 Motor Control


9. Reconnect Load Cell Connector to J11 on

Motor Control Board. Make certain the

Pink Wire on the Connector is positioned onto Pin 1 of the Motor Control Board. See

10. Set Multimeter to read 10 VDC. Make connection with Pins 1 and 2 from the side of the connector with Multimeter

Leads and take reading. See Figure 5.22.

11. If reading is not 10 VDC, replace unit Load

Cell. Refer to 6.7 Load Cell Removal and

Replacement. If reading is 10 VDC proceed

22

FIGURE 5.21

FIGURE 5.19

FIGURE 5.20


FIGURE 5.22


5.12 LOAD CELL TROUBLESHOOTING (continued)

D. Voltage from Load Cell Tests

NOTE:

It will be necessary to have two people available for the following test.

1. Set Multimeter to read 10 VDC. Make connection with Pin 3 (Blue wire) and Pin 4

(Green wire) from the side of the connector with Multimeter Leads. See

2. Press the START button. The voltage reading on Multimeter should increase as

3. Press the STOP button. The voltage reading on Multimeter should decrease as Cord

4. If voltage does not increase and decrease as described in steps 2 and 3, continue

5. Turn unit Off. Using the Pick, remove Blue wire and Green wire from connector. See

6. Connect the Multimeter Leads to the Blue and Green wires. Repeat steps 2 and 3.

7. If voltage does not increase or decrease as described in steps 2 and 3, replace unit

Load Cell. Refer to 6.7 Load Cell Removal

8. If voltage does increase and decrease as described in steps 2 and 3, replace wires into connector. Make certain the Blue wire is in the Pin 3 position and the Green wire is in the Pin 4 position. Repeat steps 2 and

3. If problem persists, proceed to step 9.

9. Locate U3 on Motor Control Board.

Connect the Red (+) Multimeter Lead to

Pin 7 of U3 and the Black (-) Lead to Pin 4 of U3. See Figure 5.25.

10. Repeat steps 2 and 3. If voltage does not increase and decrease as described in steps 2 and 3, replace Motor Control

Board. Refer to 6.5 Motor Control Board

Removal & Replacement.

RED LEAD

TO PIN 4

BLACK LEAD

TO PIN 3

FIGURE 5.23

USE PICK TO

REMOVE WIRES

FIGURE 5.24


FIGURE 5.25

23


5.13 TOUCH SCREEN TEST


Control . . . . . . . . . . Touch Screen Dims and Brightens

Touch Screen . . . . . . . . . Displays proper Screen

None

C. Touch Screen Test Procedure

1. Place unit on level work surface.

2. Plug Power Cord into grounded power

source with appropriate voltage. See

Specifications on page 8.

3. Turn unit On with Power Switch. After the

unit has completely booted, adjust the

Touch Screen Contrast with the Contrast

Control on the back of the Touch Screen

Housing. See Figure 5.26.

4. Press Touch Screen controls to verify the

Touch Screen responds and displays the

correct screen. See Figure 5.27.

D. Test Result

1. If when adjusting, Contrast Control dims

and brightens Touch Screen, unit passed

test. If Contrast Control does not dim and

brighten Touch Screen, refer to 5.14 Touch

2. If when pressing controls on Touch Screen

the proper screen does not display,

unit failed test. Calibrate Touch Screen. Refer

to 7.2 Touch Screen Calibration.

3. If nothing is visible on Touch Screen, adjust

Contrast Control. If problem persists, unit

failed test. Refer to 5.14 Touch Screen

Troubleshooting.

CONTRAST

KNOB

FIGURE 5.26

FIGURE 5.27


24


5.14 TOUCH SCREEN TROUBLESHOOTING


Voltage to Touch Screen:

J6 Connector . . . . . . . . . . . . . . . . . 5 VDC ±5%

Display Connector . . . . . . . . . . .24 VDC ±5%




C. Touch Screen Troubleshooting Procedure

1. Remove Side Covers. Refer to 6.1 Side Cover


2. Plug unit into an approved power source

and turn unit On with Power Switch.

3. Observe Motor Control Board LEDs. The

"5V OK" LED should be illuminated and

LED 3 should be flashing. See Figure 5.28.

a. If LEDs are not working properly, proceed

to step 4.

b. If LEDs are working properly, proceed to

steps 5 through 9.

4. Turn unit Off. Remove Touch Screen Ribbon

Cable from "Display" on Motor Control

Board. See Figure 5.29. Turn unit On.

a. If LEDs begin working properly, replace

Touch Screen assembly. Refer to 6.6

Touch Screen Assembly Removal and

Replacement.

b. If LEDs are not working properly, refer to

5.15 Power Supply Troubleshooting.

c. If Power Supply is functioning properly,

replace Motor Control Board. Refer to 6.5

Motor Control Board Removal and

Replacement.

5. Turn unit Off. Remove Touch Screen Ribbon

Cable from "Display" on Motor Control

Board. See Figure 5.29. Turn unit On.

6. Set Multimeter to VDC. On Connector J6,

connect the Red (+) Multimeter Lead to

Pin 1 and the Black (-) Lead to Pin 2. See

Figure 5.28. Take reading from Multimeter.

Reading should be +5 VDC.

7. Connect the Red (+) Multimeter Lead to Pin

6 and the Black (-) Lead to Pin 1 on the

Motor Control Board "Display" Connector.

See Figure 5.30 reading on Multimeter

should be 24 VDC.

8. If the voltage reads correctly from steps

5 and 6, replace the Touch Screen Assembly.

Refer to 6.6 Touch Screen Removal

9. If either of the voltages are not reading

properly as in steps 6 and 7, replace Motor

Control Board. Refer to 6.5 Motor Control


25

PIN 1


PIN 2

J6

LED 3

FIGURE 5.28

5V OK LED

FIGURE 5.29

CAUTION

Make certain Multimeter Leads are on the correct pins and do not short across any other pins to prevent destruction of the

Motor Control Board.

FIGURE 5.30


5.15 POWER SUPPLY TROUBLESHOOTING


Power Supply Input . . 100 V-240 V (50/60 Hz)

Power Supply Output . . . . . . . . . . .24 VDC ±5%



C. Power Supply Troubleshooting Procedure



2. Plug Power Cord into grounded power

source with appropriate voltage. See

Specifications on page 8.

3. Set Multimeter to read appropriate VAC.

4. Connect Multimeter Leads to the Power

Supply Fuses at the rear of Power Supply.

See Figure 5.31. Multimeter should read

same voltage as the approved power source.

a. If reading is the same as approved power

source, proceed to step 5.

b. If VAC reading is not the same as

approved power source, replace Power

Supply. Refer to 6.12 Power Supply


5. Remove Power Supply Output Harness from

Motor Control Board J5. See Figure 5.32.

6. Set Multimeter to read VDC. Connect

Multimeter Leads to the Power Supply

Output Harness. See Figure 5.33. Multimeter

reading should be 24 VDC ±5%.

a. If reading is within the specified range as

stated above, unit passed test.

b. If reading is not within the specified

range as stated above, replace Power

Supply. Refer to 6.12 Power Supply


FIGURE 5.31

FIGURE 5.32


26

FIGURE 5.33


5.16 sEMG TESTS

This test is to be performed on the Triton Traction unit only with the sEMG Module properly installed.

Perform this test on all Channels with sEMG.

A. Test Equipment Required

1.

It will be necessary to build an Attenuator for this test. See Figure 5.34 for schematic of the required Attenuator. The Attenuator must be contained in shielded enclosure.

Input connection and output connections should be separated from each other as far as possible within the confines of the shielded enclosure.

2.

Calibrated Audio Signal Generator, B-K

Precision, Model 3001.

3.

Test leads for Audio Generator to

Attenuator.

NOTE:

Audio Signal Generator must produce a sine waveform.

4.

Known good sEMG Lead Wires.

B. sEMG Test Procedures

1.

Figure 5.35 depicts the controls of the

Audio Signal Generator. Set up Audio Signal

Generator as follows:

a) Plug the Audio Signal Generator Test

Leads into Generator SYNC Ports.

b) Set the FREQ. RANGE Hz to X1.

c) Turn the amplitude knob up to

maximum.

d) Set the WAVEFORM to Sine waveform.

e) Set the ATTEN to O.

f) Set the FREQUENCY DIAL to 100.

g) Turn Audio Signal Generator On.

2.

Turn Triton On. View Home Screen for the presence of the sEMG icon. See Figure 5.36.

If icon is grey, stop test and make necessary repairs to the sEMG Module and System.

a) Make certain sEMG Module is completely

seated in unit.

b) Replace sEMG Module with a known

good sEMG Module. Refer to 6.15 sEMG

Module Removal and Replacement.


RED

ATTENUATOR SCHEMATIC

100K 1%

RED

49.9 OHM 1%

GREEN

TO AUDIO WAVEFORM

GENERATOR

49.9 OHM 1%

BLACK

BLACK

100K 1%

SET FREQUENCY RANGE

HZ TO X1

AMPLITUDE TO

MAXIMUM

TO SEMG LEAD WIRES

FIGURE 5.34

FREQUENCY

DIAL TO 100

WAVEFORM

TO SINE

ATTEN TO 0

FIGURE 5.35

sEMG ICON

TEST LEADS TO

SYNC PORTS

FIGURE 5.36

27


5.16 sEMG TESTS (continued)

3. If icons are present, connect known good

sEMG Lead Wire to the Triton Traction unit.

See Figure 5.37.


FIGURE 5.37

4. Connect the sEMG Lead Wires into the

Attenuator. Make certain the sEMG Lead

is connected to its respective color on the

Attenuator. See Figure 5.38.

NOTE:

Make certain that nothing is touching the sEMG lead wires or the attenuator box. Signals used in sEMG are very small and signal can be induced from external sources that create an unbalanced input.

5. Press the sEMG Traction icon on Home

Screen. See Figure 5.39 Reading should be

7 or less.

6. If the reading is greater than 7, replace

the sEMG Module and re-test. Refer to 6.15

sEMG Module Removal and Replacement.

FIGURE 5.38

LEAD WIRES TO THEIR

RESPECTIVE COLORS

ON ATTENUATOR

28

FIGURE 5.39


5.16 sEMG TESTS (continued)

7. Make certain the Audio Signal Generator

is set up per 5.16, part B, steps 1, a) through

1, g). Connect the Audio Signal Generator

Test Leads from the Generator SYNC Ports to

the Attenuator (make certain test leads are

connected red to red and black to black).

5.40.

8. View the Triton sEMG Screen. The Channel

should read between 604 and 738.

If the Channel reads below 604 or greater

than 738, replace the sEMG Module and

re-test. Refer to 6.15 sEMG Module Removal

Replacement.

C. sEMG Test Results

If the sEMG Channel fails any part of the tests as described in 5.16, B, steps 2 through 8, then the module fails the test.

1.

Make certain the sEMG Module is completely seated in the Triton unit.

2.

Replace the sEMG Module and re-test.

Refer to 6.15 sEMG Module Removal and

Replacement. If the problem continues, perform step 3 below.

3.

Replace the Motor Control Board and re-test. Refer to 6.5 Motor Control Board

Removal and Replacement. If the problem continues after performing steps 2 and 3 above proceed to step 4 below.

4.

Replace the Touch Screen Assembly and re-test. Refer to 6.6 Touch Screen Assembly

Removal and Replacement.

FIGURE 5.40


29

6 REMOVAL & REPLACEMENT

6.1 SIDE COVER REMOVAL & REPLACEMENT


A. Part Numbers

Side Cover (2 Req'd) . . . . . . . . . . . . . . . . . . . 47857

• 3/32 in Allen Wrench

• Flat Blade Screwdriver

• #1 Phillips Screwdriver

C. Removal of Side Covers

1. Remove Patient Interrupt Switch Hook

Screw Cover with a Flat Blade Screwdriver.

See inset at Figure 6.1.

2. Remove Patient Interrupt Switch Hook

Screw using a #1 Phillips Screwdriver. See

3. Lay unit on its side on a clean, soft work surface.

4. Using the 3/32 in Allen Wrench, remove the

three Side Cover Mounting Screws from the

bottom of the unit. See Figure 6.2.

5. Slide side cover from under Top Cover.

6. Turn unit over onto opposite side and

repeat steps 2-5.

D. Replacement of Side Covers

1. Position Side Cover Top Mounting Tab

between plastic of Top Cover and Touch

Screen Mounting Plate. See Figure 6.3.

2. Slide cover into position and secure with

three socket head screws using the 3/32 in

Allen Wrench. Refer to Figure 6.2.

NOTE:

Do not overtighten mounting screws.


FIGURE 6.1

SIDE COVER

MOUNTING SCREWS

FIGURE 6.2

30

FIGURE 6.3


6.2 TOP AND CORD GUIDE COVER REMOVAL & REPLACEMENT


A. Part Numbers

•

Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47856

•

Cord Guide Cover . . . . . . . . . . . . . . . . . . . . 47872

•


•


•

Touch Screen to Cover Assembly Jig

C. Removal of Top and Cord Guide Covers



2. Position unit upright on base and untie

Traction Cord from Knuckle. Refer to

page 41, step 11 Traction Cord Removal &

Replacement.

3. Disconnect the Touch Screen Ribbon

Cable from the Motor Control Board. See

4. Using the #1 Phillips Screwdriver, remove

the two Top Cover Mounting Screws from

each side of the unit. See Figure 6.5.

NOTE:

To remove the Touch Screen Assembly from the

Top Cover refer to 6.6 Touch Screen Removal &

Replacement.

5. Carefully lift the Top Cover away from unit

and position into Touch Screen to Cover

Assembly Jig. See Figure 6.6.


the four Cord Guide Cover Mounting

Screws. See Figure 6.6.

D. Replacing Top and Cord Guide Covers

1. With Top Cover positioned onto the Touch

Screen to Cover Assembly Jig, place the

Cord Guide Cover into position. Secure with

the four Cord Guide Cover Mounting


2. Position the Top Cover Assembly onto the

unit chassis. Secure into position on the

standoffs with the four Top Cover Mounting

Screws (two on each side). See Figure 6.5.

3. Connect the Touch Screen Ribbon Cable to

the "Display" Connector on the Motor

Control Board. See Figure 6.4.

4. Install Side Covers. Refer to 6.1 Side Cover


31

WHEN INSTALLING, RIBBON CABLE BLACK STRIP MUST BE

TOWARD THE TOP OF THE MOTOR CONTROL BOARD.

FIGURE 6.4

TOP COVER MOUNTING SCREWS

TWO ON EACH SIDE

FIGURE 6.5

FIGURE 6.6


CORD GUIDE COVER

MOUNTING SCREWS


6.3 REAR COVER REMOVAL & REPLACEMENT



A. Part Numbers

Rear Cover Assembly . . . . . . . . . . . . . . . . . .48110

•


•


C. Removal of Top and Cord Guide Covers

1. Remove IEC Connector Cover. See



3. Remove Top Cover Assembly. Refer to 6.2,

part C, steps 1-5.

4. Using the 3/32 in Allen Wrench, remove

the four Rear Cover Mounting Screws. See

NOTE:

To replace the Rear Cover with a new part, remove the

Power Switch, Mains Connector, and USB Board from the old Rear Cover for re-installation onto the new part. See Figure 6.9.

It is not necessary to remove Harnesses from Power

Switch, Mains Connector, or USB Board unless these components are to be replaced.

D. Replacing Rear Cover

1. Replace existing Rear Cover

a. Secure Rear Cover to chassis with four

Rear Cover Mounting Screws. See

b. Install Top Cover Assembly. Refer to 6.2,

part D, steps 2 and 3.

c. Install Side Covers. Refer to 6.1, part D,

steps 1 and 2.

2. Replace with new Rear Cover

a. Install existing Power Switch, Mains

Connector, and USB Board to new Rear

Cover.

b. Secure Rear Cover to chassis. See

c. Install Top Cover Assembly. Refer to 6.2,


d. Install Side Covers. Refer to 6.1, part D,

steps 1 and 2.

NOTE:


32

REAR COVER

MOUNTING SCREWS

FIGURE 6.7

FIGURE 6.8

USB BOARD

FIGURE 6.9

IEC CONNECTOR COVER

POWER SWITCH

MAINS CONNECTOR


6.4 FRONT COVER REMOVAL & REPLACEMENT


A. Part Numbers

Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . .47858

•


•


•

Needle Nose Pliers

C. Removal of Front Cover



2. Remove Top Cover Assembly. Refer to 6.2,

part C, steps 2-5.

3. Disconnect the Patient Interrupt Switch

Jack from the Motor Control Board. See

4. Using the 3/32 in Allen Wrench, remove

the four Front Cover Mounting Screws. See

NOTE:

To replace the Front Cover with a new part, remove the Patient Interrupt Switch Jack from the old Front

Cover for re-installation onto the new part. See

Figure 6.12.

D. Replacing Front Cover

1. Replacing existing Front Cover

a. Connect Patient Interrupt Switch Jack to

the Motor Control Board. See Figure 6.10.

b. Secure the Front Cover to the chassis

with the four Front Cover Mounting





steps 1 and 2.

2. Replacing with new Front Cover

a. Install Patient Interrupt Switch Jack into

new Front Cover. See Figure 6.12.

b. Perform steps 3-4 above in reverse order.




steps 1 and 2.

NOTE:


33


PATIENT INTERRUPT

SWITCH HARNESS

FIGURE 6.10

FRONT COVER

MOUNTING SCREWS

FIGURE 6.11


SWITCH JACK

FIGURE 6.12



The remaining removal and replacement procedures in this section require that the following be performed after component or assembly replacement to ensure proper alignment and operation of the unit:

1. COMPLETE CALIBRATION OF UNIT

AND

2. MINIMUM OF 2 HOUR BURN IN OF UNIT AFTER SUCCESSFUL CALIBRATION

Failure to perform either of these procedures after a component or assembly replacement will void warranty and may result in injury to patients and severe equipment damage.

34


6.5 MOTOR CONTROL BOARD REMOVAL & REPLACEMENT


A. Part Numbers

Motor Control Board . . . . . . . . . . . . . . . . . .47803

•


•


C. Removal of Motor Control Board



2. Disconnect all seven harnesses from the



the four Motor Control Board Mounting


D. Replacing Motor Control Board

1. Position Motor Control Board over chassis

standoffs and secure into position with the

screws removed in step 3 above.

2. Install Harnesses to the Motor Control

Board. See Figure 6.13.

3. Perform complete Calibration and Burn In

NOTE:


This component removal and replacement procedure requires that the following be performed after component or assembly replacement to ensure proper alignment and operation of the unit:

COMPLETE CALIBRATION OF UNIT Refer to

Section 7

AND

MINIMUM OF 2 HOUR BURN IN OF UNIT AFTER

SUCCESSFUL CALIBRATION Refer to Section 7

Failure to perform either of these procedures, after a component or assembly replacement will void warranty and may result in injury to patients and/or severe equipment damage.

LOAD CELL HARNESS

USB HARNESS

TOUCH SCREEN

HARNESS

SOLENOID HARNESS

MOTOR HARNESS


SWITCH HARNESS

POWER SUPPLY

HARNESS

FIGURE 6.13

MOTOR CONTROL

BOARD MOUNTING

SCREWS

FIGURE 6.14

35



6.6 TOUCH SCREEEN ASSEMBLY REMOVAL & REPLACEMENT


A. Part Numbers

Touch Screen Assembly . . . . . . . . . . . . . . .48063

•


•

Flat Blade Screwdriver

•


C. Removal of Touch Screen Assembly



2. Remove the Top Cover. Refer to 6.2 Top and

Cord Guide Cover Removal & Replacement,

part C, steps 2-5.

3. Using the Flat Blade Screwdriver, remove

the four Top Moulding Plate Mounting

Screws. When removing the Top Moulding

Plate, guide the Touch Screen Ribbon Cable

through the opening. See Figure 6.15.

4. Using the Flat Blade Screwdriver, remove

the four Turn Table Plate Retaining Screws.

5. Squeeze the two Touch Screen Assembly

Tabs and push the Touch Screen Assembly

out of the Top Cover. See Figure 6.17.

TOP MOULDING PLATE

MOUNTING SCREWS

FIGURE 6.15

TURN TABLE PLATE

MOUNTING SCREWS


FIGURE 6.16

36

FIGURE 6.17


6.6 TOUCH SCREEN ASSEMBLY REMOVAL & REPLACEMENT (continued)


D. Replacing Touch Screen Assembly

1. Place new Touch Screen Assembly into

Touch Screen to Cover Assembly Jig.

2. Position Top Cover over the Touch Screen

Assembly aligning the mounting hole to the

Touch Screen Assembly.

3. Slide the Top Cover over the Touch Screen

Assembly until the Mounting Tabs click into

position. See Figure 6.18.

4. Position the Turntable Plate and secure the

four screws with the #2 Phillips Screwdriver.

5. Position the Top Moulding Plate. Thread the

Touch Screen Ribbon Cable through the

opening in the Top Moulding Plate as

shown in Figure 6.20. Secure the four Top

Moulding Plate screws with the #2 Phillips

Screwdriver. Refer to Figure 6.15.

6. Install Top Cover Assembly. Refer to 6.2,


7. Install Side Covers. Refer to 6.1, part D,

steps 1 and 2.


NOTE:


This removal and replacement procedure requires that the following be performed after component or assembly replacement to ensure proper alignment and operation of the unit:

1. COMPLETE CALIBRATION OF UNIT


AND

2. MINIMUM OF 2 HOUR BURN IN OF UNIT

AFTER SUCCESSFUL CALIBRATION



37

FIGURE 6.18

TURN TABLE PLATE

MOUNTING SCREWS

FIGURE 6.19

FIGURE 6.20



6.7 LOAD CELL ASSEMBLY REMOVAL & REPLACEMENT



A. Part Numbers

Load Cell Assembly . . . . . . . . . . . . . . . . . . . .48009

•


•

4 mm Hex Key Socket and Ratchet

•

Calibrated Torque Wrench- 200 inch pound or 2,500 Newton meter minimum capacity.

C. Removal of Load Cell Assembly





part C, steps 2-5.

3. Remove Rear Cover. Refer to 6.3 Rear Cover


4. Remove the Clamp Spring Assembly.

Refer to 6.8 Clamp Spring Assembly


5. Disconnect the Load Cell Harness from the


6. Using the 4 mm Hex Key Socket and

Ratchet, remove the two Load Cell

Mounting Screws and Flat Washers from

each side of the Chassis. See Figure 6.22.

7. Lift Load Cell Assembly out of Chassis. See


MOUNTING SCREWS

2 EACH SIDE

FIGURE 6.21

FIGURE 6.22

LOAD CELL

ASSEMBLY


38

FIGURE 6.23


6.7 LOAD CELL ASSEMBLY REMOVAL & REPLACEMENT (continued)


D. Replacement of Load Cell Assembly

1. Place Load Cell Assembly into Chassis and

hold in position while hand starting the

Load Cell Mounting Screws and Flat

Washers. See Figure 6.24.

2. Hand tighten the Load Cell Mounting

Screws.

3. Install the Clamp Spring Assembly.

Refer to 6.8 Clamp Spring Assembly

4. Use the Torque Wrench and 4 mm Hex

Key Socket to torque the Load Cell

Mounting Screws to 35 Nm (84 in lbs).

5. Route Load Cell Harness through Harness

Clips on the Chassis and connect to Motor

Control Board. See Figure 6.25.

6. Route Traction Cord through the Load Cell

Assembly Pulley and through the Chassis

Upper Guide Pulley. See Figure 6.26.

7. Install Rear Cover. Refer to 6.3 Rear Cover

8. Install Top Cover. Refer to 6.2 Top and Cord

Guide Cover Removal & Replacement.


10. Perform complete Calibration and Burn In unit.

FIGURE 6.24

FIGURE 6.25





AND





39

FIGURE 6.26


6.8 CLAMP SPRING ASSEMBLY REMOVAL & REPLACEMENT



A. Part Numbers

Clamp Spring Assembly . . . . . . . . . . . . . . .48023


C. Clamp Spring Assembly Removal





part C, steps 2-5.



4. Remove the four Clamp Spring Assembly

Mounting Screws. See Figure 6.27.

5. Turn the Clamp Knob Counterclockwise

until it is completely disengaged from the

Clamp Plate. See Figure 6.28.

D. Clamp Spring Assembly Replacement

1. Position the Clamp Spring Assembly at the

Chassis and rotate Clamp Knob until the

threaded portion is fully engaged in the

Clamp Plate and the Clamp Spring

Assembly Mounting Bracket is aligned with

the respective mounting holes in the

Chassis. Secure with the four Clamp Spring

Assembly Mounting Screws.



3. Install Top Cover. Refer to 6.2 Top and

Cord Guide Cover Removal & Replacement.




FIGURE 6.27

FIGURE 6.28

CLAMP SPRING

ASSEMBLY

SCREWS


CLAMP KNOB

CLAMP SPRING

ASSEMBLY

MOUNTING SCREWS


CLAMP PLATE




AND





40


6.9 TRACTION CORD REMOVAL & REPLACEMENT


A. Part Numbers

Traction Cord . . . . . . . . . . . . . . . . . . . . . . . . . .48031

•

•



•

Needle Nose Pliers

•

Tape Measure

C. Clamp Spring Assembly Removal





part C, steps 2-5.



4. Remove the Clamp Spring Assembly. Refer

to 6.8 Clamp Spring Removal and

Replacement.

5. While holding the Cord Tension Spring

Housing in position with one hand, loosen

the retaining screw with the other hand.

6. Gradually release the spring tension by

allowing the Spring Housing to slowly

rotate in the hand. Leave the Housing

Retaining Screw loose.

7. Manually release the Solenoid from the

Large Driven Gear and simultaneously

pull the Traction Cord through the unit

front until the Traction Cord stops. See

NOTE:

Make certain the Traction Cord Knot is facing the rear of the unit.

8. Release the Solenoid, making certain it fully

engages the teeth of the Large Driven Gear.

NOTE:

It may be necessary to slightly jog the Large Driven

Gear to facilitate tooth engagement.

9. Remove the Traction Cord Knuckle. Refer to

page 41, step 11. Using the Needle Nose

Pliers, pull the Traction Cord Knot from the

Traction Cord Spool and completely pull the

Traction Cord out of unit. See Figure 6.31.

41

FIGURE 6.29

FIGURE 6.30

FIGURE 6.31




6.9 TRACTION CORD REMOVAL & REPLACEMENT (continued)

D. Traction Cord Replacement

1. Route Traction Cord through the Traction

Cord Spool, Load Cell Pulley, and Top Guide

• Unplug the unit from the power source before attempting removal or replacement procedures to

• prevent electrical shock.

It is not recommend tying a new knot in a cord that has frayed or failed in use or is worn in an area from constant use. The cord must be replaced.

NOTE:

The left side of the Chassis incorporates a Window to facilitate proper routing of the Traction Cord.

TOP GUIDE PULLEY

LOAD CELL PULLEY

TRACTION CORD SPOOL

TRACTION CORD

ROUTING WINDOW

FIGURE 6.32

42




2. Pull enough of the Traction Cord through

the Traction Cord Spool to allow the knot

to be tied.

3. Tie a Figure Eight (Flemish, Savoy) Knot

in the end of the Cord passing through the

Traction Cord Spool. See Figure 6.33.

1

Do not use any other knot styles in the Cord other than those specified in this manual. Use of other knot styles could cause Cord to completely disengage from the system causing serious injury to patient and personnel.

4. Trim any fraying from the Traction Cord

leaving 19 mm (0.75 in) of Cord outside the

Figure Eight (Flemish, Savoy) Knot.

5. Singe the Cord end until the outer jacket

and inner core of the Traction Cord melt

together. See Figure 6.34A.

6. Pull other end of Traction Cord until the

Figure Eight (Flemish, Savoy) Knot is

completely seated within the Traction Cord

Spool. See Figure 6.34B.

NOTE:

It may be necessary to use a long, thin tool such as a

Flat Blade Screwdriver to properly tuck the Figure Eight

(Flemish, Savoy) Knot into the Traction Cord Spool.

3

FIGURE 6.33

4


2

43

FIGURE 6.34A

FIGURE 6.34B




7. Route Traction Cord through the Front

Cord Guide Support.

8. Route Traction Cord through the Top

Cover and place the Top Cover in Position

on the Chassis. See Figure 6.35. Do not

secure Top Cover at this time.

9. Inspect Traction Cord Knuckle for damage

and wear. Replace if damaged or worn.

10. Route Traction Cord through Traction

Cord Knuckle Cover and Cord Knuckle. Tie

an Overhand or Half Knot in the end of

the Traction Cord leaving 25.5 mm

(1.00 in) of Traction Cord outside the

knot. See Figure 6.36.

11. Trim any fraying from the end of the

Traction Cord and singe the Cord end

until the outer jacket and inner core of

the Traction Cord melt together. Make

certain at least 19 mm (0.750 in) of

Traction Cord still remains outside the

knot. See Figure 6.36 inset.

FIGURE 6.35


Do not use any other knot styles in the Cord other than those specified in this manual. Use of other knot styles could cause Cord to completely disengage from the system and may cause serious injury to patient and personnel.

12. Secure the knot inside the Traction Cord

Knuckle ensuring the loose end enters

the Bore inside the Traction Cord

Knuckle. See Figure 6.37. Slide Traction

Cord Knuckle Cover into position over the

knot. See Figure 6.37 inset.

NOTE:

It may be necessary to use a long, thin tool such as a

Flat Blade Screwdriver to properly tuck the loose end of the Traction Cord into the Bore of the Traction Cord

Knuckle.

FIGURE 6.36

FIGURE 6.37

44




NOTE:

If adjusting Spring Tension only and not replacing the

Traction Cord, it will be necessary to remove the Side

Covers and have available the Tools required in 6.9, B.

13. Manually release the Solenoid and

simultaneously fully extend the Traction

Cord. Release Solenoid and make certain

the Solenoid Gear fully engages the

Large Driven Gear. See Figure 6.38.

14. With the Cord fully extended, rotate the

Cord Spring Housing clockwise until

the Cord Spring is completely wound,

then rotate counterclockwise 1/4 to 1/2

turn. Hold the Cord Spring Housing in

position and tighten the Retaining Screw

using the 5/32 in Allen Wrench. See

NOTE:

Overtightening of the Cord Spring Housing Retaining

Screw will break the housing and cause the spring to lose tension.

15. While holding on to the Traction Cord,

manually release the Solenoid and allow

the Traction Cord to retract.

16. Manually release the Solenoid and

simultaneously fully extend the Traction

Cord. Release Solenoid and make certain

it fully engages the Large Driven Gear.

17. Using Tape Measure, measure the length

of the Cord from the Cord Guide Cover to

the end of the Harness Clip. See

Figure 6.40. Measurement should be

96.5 cm to 106.5 cm (38 in to 42 in).

a) If measurement is less than 96.5 cm

(38 in), Spring Tension is too tight.

Loosen the Spring Housing Retaining

Screw and allow the housing to release

no more than 1/2 revolution of tension.

Tighten Spring Housing Retaining

Screw and repeat steps 15 and 16.

b) If measurement is more than 106.5 cm

(42 in), increase Traction Cord Spring

Tension by no more than 1/2

revolution.

18. Repeat step 17 a or b until Cord

dimension is correct.

45

FIGURE 6.38

FIGURE 6.39

FIGURE 6.40





19. Install Clamp Spring Assembly. Refer to

6.8 Clamp Spring Assembly Removal &

Replacement.

20. Install Rear Cover. Refer to 6.3 Rear Cover


21. Install Top Cover. Refer to 6.2 Top and

Cord Guide Cover Removal &

Replacement.

22. Install Side Covers. Refer to 6.1 Side Cover


23. Perform complete Calibration and Burn In unit.




AND






46


6.10 CORD TENSION SPRING REMOVAL & REPLACEMENT


A. Part Numbers

Cord Tension Spring . . . . . . . . . . . . . . . . . . .80653

•


•


C. Cord Tension Spring Removal





part C, steps 2-5.

3. While holding the Cord Tension Spring

Housing with one hand. Loosen the

retaining screw with the other hand using

the 5/32 in Allen Wrench. See Figure 6.41.

4. Gradually allow the Spring Housing to

rotate in the hand releasing spring tension.

5. Rotate the Cord Tension Spring Housing

until the hole in the face aligns with the

Spring Mounting Screw. Remove screw with

the 3/32 in Allen Wrench. See Figure 6.42.

6. Remove the Cord Tension Spring Housing

Mounting Screw. See Figure 6.43.

7. Remove Cord Tension Spring and Housing

SPRING

MOUNTING

SCREW

FIGURE 6.41

FIGURE 6.42


47

FIGURE 6.43


6.10 CORD TENSION SPRING REMOVAL & REPLACEMENT (continued)


D. Cord Tension Spring Replacement

1. Position new Cord Tension Spring in

Housing as shown in Figure 6.44.

2. Place Spring Mounting Screw through hole

in face of the Housing and through the

Cord Tension Spring Mounting Loop. Leave

the head of the Spring Mounting Screw

protruding through the Housing. See

3. Position the Spring and Housing assembly

in the mounting position on the Chassis.

Start the Spring Mounting Screw using the

3/32 in Allen Wrench. Tighten Mounting

Screw until Cord Tension Spring Mounting

Loop is secure then, back the screw out one

complete revolution. See Figure 6.46.

4. Position the Spring and Housing so that the

Housing Mounting Screw can be started.

Start screw with the 5/32 in Allen Wrench.

5. Adjust Spring Tension. Refer to page 42.



Replacement.




FIGURE 6.44

FIGURE 6.45





AND





48

FIGURE 6.46


6.11 SOLENOID ASSEMBLY REMOVAL & REPLACEMENT


A. Part Numbers

Solenoid Assembly . . . . . . . . . . . . . . . . . . . . 48014


•


•

Solenoid Assembly Mounting Jig(P/N 48139)

C. Solenoid Assembly Removal



2. Make certain the Cord is fully retracted. If

necessary, manually retract. Refer to

3. Disconnect the Solenoid Assembly Harness

from Motor Control Board. See Figure 6.47.


two Solenoid Assembly Mounting Screws.

D. Solenoid Assembly Replacement

1. Position the Solenoid Assembly Mounting

Jig onto the Shafts of the Large Driven Gear

and the Motor Gear. See Figure 6.49.

2. Position the Solenoid Assembly so gears are

fully seated and the front and bottom of the

Bracket are against the Solenoid Assembly

Mounting Jig. Secure with screws. See

3. Connect Solenoid Assembly Harness to








AND

2. MINIMUM OF 2 HOUR BURN IN OF UNIT AFTER

SUCCESSFUL CALIBRATION



49

SOLENOID

MOUNTING

SCREWS

FIGURE 6.47

SOLENOID

MOUNTING

SCREWS

FIGURE 6.48

SOLENOID ASSEMBLY

MOUNTING JIG P/N 48139

FIGURE 6.49



6.12 POWER SUPPLY REMOVAL & REPLACEMENT



A. Part Numbers

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . .27265

Power Supply Shield . . . . . . . . . . . . . . . . . .27592

•


•


•

Digital Multimeter (Set to VDC)

C. Power Supply Removal




Cord Guide Cover Removal & Replacement.



4. Disconnect the Power Supply Input

Harnesses from the Mains Connector. See

5. Disconnect Power Supply Output

Harness from the Motor Control Board. See


Ground Harnesses from the Chassis. See

7. Using the Multimeter set to VDC discharge

the Power Supply Capacitor at C4. See

POWER SUPPLY

INPUT HARNESSES

FIGURE 6.50A

FIGURE 6.50B

FIGURE 6.51


• Discharge the C4 Capacitor prior to complete removal of the Power Supply.


the four Power Supply Mounting Screws.

9. Grasp the sides of the Power Supply and

carefully remove from the chassis.

FIGURE 6.52

50


6.12 POWER SUPPLY REMOVAL & REPLACEMENT (continued)

POWER SUPPLY

MOUNTING SCREWS


GROUND

HARNESSES

D. Power Supply Replacement

1. Prior to handling new Power Supply,

discharge the Capacitor at C4. Refer to


SHIELD

BLACK SIDE TOWARD

POWER SUPPLY


• Discharge the C4 Capacitor prior to handling of the new Power Supply.

2. Make certain the Shield is in place with

the nonconductive (black) side toward

the Power Supply. Position the Power

Supply on the Chassis. Secure with the

four Power Supply Mounting Screws. See

3. Using the 3/32 in Allen Wrench and Ground

Harness Mounting Screw, secure the

Ground Harnesses from the Power Supply

and the Mains Connector to the Chassis.

4. Connect the Power Supply Input Harnesses

to the Mains Connector Harnesses. See

5. Connect the Power Supply Output

Harness to the Motor Control Board. See





Replacement.




POWER SUPPLY

MOUNTING SCREWS

FIGURE 6.53

POWER SUPPLY

INPUT HARNESSES

FIGURE 6.54A

FIGURE 6.54B




AND





51


6.13 MOTOR ASSEMBLY REMOVAL & REPLACEMENT


A. Part Numbers

Motor Assembly . . . . . . . . . . . . . . . . . . . . . . .48019

•


•

3 mm Allen Wrench

•

7 mm Box End Wrench

•

Solenoid Assembly Mounting Jig

C. Motor Assembly Removal



2. Make certain Traction Cord is completely

retracted. If necessary, manually release

Solenoid to retract Cord.

3. Loosen the Solenoid Mounting Screws

enough to rotate Solenoid Gear up and off

of the Motor Gear. See Figure 6.55.

4. Disconnect the Motor Harness from the


5. Using the 3 mm Allen Wrench and 7 mm

Boxed End Wrench, remove the four Motor

Assembly Mounting Screws. See Figure 6.57.

6. Remove Motor Assembly from Chassis.

NOTE:

It may be necessary to remove the Motor Control

Board. Refer to 6.5 Motor Control Board Removal &

Replacement.

FIGURE 6.55

FIGURE 6.56


52

FIGURE 6.57


6.13 MOTOR ASSEMBLY REMOVAL & REPLACEMENT (continued)


D. Motor Assembly Replacement

1. Position new Motor Assembly into Chassis

and secure with the four Motor Assembly

Screws, Lock washers, and Nuts. See

2. Position and adjust the Solenoid. Refer to

6.11 Solenoid Assembly Removal &

Replacement.

NOTE:

If Motor Control Board was removed, re-install before proceeding to step 3 below.

3. Connect the Motor Assembly Harness to

the Motor Control Board. See Figure 6.59.




FIGURE 6.58





AND





FIGURE 6.59

53


6.14 MOTOR DRIVE GEAR REMOVAL & REPLACEMENT

SOLENOID REMOVED

FOR CLARITY


A. Part Numbers

Motor Drive Gear . . . . . . . . . . . . . . . . . . . . . .48024

•


•


•

Tape Measure

C. Motor Drive Gear Removal



2. Make certain Traction Cord is completely

retracted. If necessary, manually release

Solenoid to retract Cord.

3. Rotate Motor until Drive Gear Set Screw is

accessible. See Figure 6.60.

4. Using the 3/32 in Allen Wrench, loosen the

Drive Gear Set Screw and pull the Drive

Gear from Motor Shaft.

D. Motor Drive Gear Replacement

1. Install new Motor Drive Gear onto Motor

Shaft. Align Set Screw with the Key Slot in

the Motor Shaft. See Figure 6.61.

2. Adjust the Gear position until the face of

the gear is 9.5 mm (3/8 in) from the face of

the shaft. See Figure 6.61.

3. Tighten the Set Screw with the 3/32 in Allen

Wrench.



LOOSEN SET SCREW

TIGHTEN SET SCREW

9.5 MM

3/8"

FIGURE 6.60

FIGURE 6.61





AND





54


6.15 sEMG MODULE REMOVAL & REPLACEMENT


A. Part Numbers

sEMG Module . . . . . . . . . . . . . . . . . . . . . . . . . .48019


•


•

3 mm Allen Wrench

•

7 mm Box End Wrench

•


C. sEMG Module Removal

1. Lay the Triton Traction unit on its side. See

2. Depress the two sEMG mounting tabs in

and simultaneously pull the sEMG Module

free from the Triton Traction unit. See

D. sEMG Module Replacement

1. Position the sEMG Module so that the

sEMG Module Contacts align with the sEMG

Module Connector inside the Triton Traction unit.

2. Push the sEMG Module into the Triton unit

until the sEMG Module is completely seated

and the Mounting Tabs snap into position

locking the sEMG module in place. See


FIGURE 6.62

PRESS TABS AND PULL

OUT sEMG MODULE

FIGURE 6.63

55

7 CALIBRATION

7.1 UNIT CALIBRATION


Certain removal and replacement procedures require that complete Unit Calibration and Burn In be performed prior to placing the unit back into service.

Failure to perform either of these procedures after certain component or assembly replacement will void warranty and may result in injury to patients and severe equipment damage.

A. General Information

1. The Calibration and Burn-In Procedures in

this section must be performed annually

and when field service requires removal and

replacement of certain components.

2. The Calibration Procedure requires use of

US lb Weight Measurements. The software

is fixed and will not perform conversions of

Metric Weight Measurements for this critical

procedure. Therefore, when constructing

and equipping the Calibration Fixture, it is

required that the Electronic Load Cell

Components be capable of expressing

US lbs.

3. The fabrication of a Calibration Fixture is

required for these units.

FIGURE 7.1

Calibration Fixture with calibrated Strain Meter

C. Unit Calibration Procedure

1. Place unit on Calibration Fixture and secure

in position by tightening the unit Lock

Knob. See Figure 7.1.

2. Connect unit to an approved power source.

3. Turn unit On.

4. Release Traction Cord and connect

Accessory Clip to the Strain Meter. Leave

slack in Cord. See Figure 7.2.

5. Zero Strain Meter LCD.

SLACK IN

CORD

STRAIN METER

ACCESSORY CLIP TO

LOAD CELL

FIGURE 7.2

When performing Unit Calibration Procedure, the

Calibration Fixture Load Cell must be set to US lbs.

56


7.1 UNIT CALIBRATION (continued)

6. Press the Clinical Resources button. See

7. Simultaneously press the START, STOP, and

Clinical Resources buttons. See Figure 7.4.

FIGURE 7.3


8. Press "Zero the Load Cell" on Touch Screen.

9. When the screen message appears, "Load

Cell has been zero calibrated!", touch the

Touch Screen anywhere to continue.

FIGURE 7.4

57

FIGURE 7.5



10. Hold onto Traction Cord and press Rope

Release to remove all slack from Traction

Cord.

11. Press Calibrate Load Cell Bias on the Touch


CALIBRATE LOAD CELL

BIAS


12. While watching the Strain Meter LCD,

Figure 7.7A, press the Up and Down

Arrow buttons, Figure 7.7B until 100 lbs is displayed on LCD.

13. Press Back icon on Touch Screen to set and accept calibration measurement.

NOTE:

Unit will display a validation message reading

"Returning to zero" while releasing tension on the

Traction Cord.

14. Press Rope Release and pull enough Cord out to connect the Accessory Hook to the

Lower Ring on the Calibration Fixture. See

7.8.

15. Allow excess Traction Cord to feed back into unit and release Rope Release.

STRAIN METER LCD

FIGURE 7.7A

FIGURE 7.6

FIGURE 7.7B

58

ACCESSORY CLIP TO

LOWER RING

FIGURE 7.8



16. Press Calibrate Motor Current on the

Touch Screen. See Figure 7.9.

17. Unit will display "Motor Current

Calibration completed OK." When Motor

Current Calibration is complete. Touch

anywhere to continue.

7.2 TOUCH SCREEN CALIBRATION

NOTE:

If the unit is not in the Calibration Mode, refer to 7.1, C, steps 6-7 to place unit in Calibration Mode.

A. Equipment Required

None

B. Touch Screen Calibration Procedure

1. Press Touch Screen Calibration on Touch


2. Follow instructions on Touch Screen.

FIGURE 7.9

FIGURE 7.10


CALIBRATE MOTOR

CURRENT

59


7.3 UNIT BURN IN


Certain removal and replacement procedures require that complete Unit Calibration and Burn In be performed prior to placing the unit back into service.

Failure to perform either of these procedures after certain component or assembly replacement will void warranty and may result in injury to patients and severe equipment damage.

The following Burn In procedure must be allowed to cycle for a minimum of two hours after Calibration

Procedures have been performed, but prior to placing the unit back into service.

A. Specifications

Burn In Intermittent Pull . . . 0-200 US lbs ±10%

Burn In Time Period . . . . . . . . .2 hours minimum


Calibration Fixture with calibrated Strain Meter.

C. Burn In Set Up

1. Place unit on Calibration Fixture and secure

in position by tightening the unit Lock

Knob. See Figure 7.11.

2. Connect unit to an approved power source.

3. Turn unit On.

4. Release Traction Cord and connect

Accessory Clip to the Load Cell. See

5. Zero Load Cell.

D. Burn In Procedure

1. Perform Burn In Set Up.

2. Press the Clinical Resources button.

3. Simultaneously press the STOP, Clinical

Resources, and PAUSE buttons to access the

4. Press Start Burn-In on the Touch Screen. See

5. After unit has cycled for a minimum of two

hours, press the STOP button. Unit will

return to the Home Screen.

6. Set up unit for a 100 lb Static pull. Start the

pull and verify the readout for the Load Cell

is 100 lbs ±10%.

E. Burn-In Result

1. If Load Cell Readout is outside the specified

range during the Static pull, perform Unit

Calibration Procedure and Burn In

procedure. Refer to pages 51-55.

2. If Load Cell Readout is within Specified

Range during Static pull, unit is ready to be

placed into service.

START BURN IN

FIGURE 7.11

FIGURE 7.12

60

8 PARTS

8.1 TOP COVER ASSEMBLY

1

8

3

7

3

6


2

3

4

5

ITEM PART

NO.

1 47856

6

7

8

4

5

2

3

48007

27137

60803

48072

48062

47896

47873

Top Cover

Top Moulding Plate

Screw

Screw

Touch Screen Assembly

Turn Table Plate

Hook Cover

Cord Guide Cover

DESCRIPTION

61

QTY

1

1

2

1

4

1

1

10

8 PARTS

8.2 SIDE COVERS

6

1

See Page 61


1

2

2

ITEM PART

NO.

1 47857

4

5

2

3

6

47884

47871

47870

27306

48115

Side Cover

Side Badge

Knob Cap

Lock Knob

IEC Connector Cover

Triton Badge

DESCRIPTION

62

5

3

4

QTY

2

1

1

2

1

1

8 PARTS

8.3 FRONT AND REAR COVERS

5

8

5

7-7A

6

1

2

1

3

3

3


4

ITEM PART

NO.

1 47858

4

5

2

3

48038

48070

48110

47851

7A

8

6

7

48054

47878

48123

48040

DESCRIPTION

Front Cover

Left Spring

Stand Off

Rear Cover Assembly (includes wiring and hardware)

Screw

Right Spring

Front Infi ll (Not Illustrated) eEMG Module (Not Illustrated)

Patient Switch Receptacle

63

5

QTY

1

1

1

1

4

1

1

1

8

8 PARTS

8.4 BASE AND EXTRUSION ASSEMBLY

7

6

5

6

3

4

7

ITEM PART

NO.

1 47833

2 70208

21387

47832

60014

62951

48019

Extrusion

Hex Nut

Flat Washer

Base Plate

Anti Skid Feet

Screw

Motor Assembly

DESCRIPTION

64

1

2


3

4

5

QTY

4

8

8

1

1

1

8

8 PARTS

8.5 CHASSIS ASSEMBLY

1

2

3

2

4

5

14

6

7


8

13

ITEM PART

NO.

1 48009

10

11

12

13

14

15

8

9

6

7

4

5

2

3

48097

47850

47803

70777

78155

48008

21387

48102

70369

48078

47998

48031

47851

47889

Load Cell Assembly

Flat Washer

Shoulder Bolt

Top Guide Pulley

Top Guide Mounting Spacer

Top Guide Pulley Axle

Traction Cord

Screw

Spring Housing

Front Cover Mounting Bracket

Stand Off

Motor Control Board

Screw

Cable Guide

E-Clip

15

12

11

DESCRIPTION

8

65

10

9

QTY

1

4

2

1

1

1

2

4

4

1

4

1

4

2

2

8 PARTS

8.6 TRACTION CORD SPRING ASSEMBLY AND POWER SUPPLY

12

13

14

1


2

3

4

5

6

11

ITEM PART

NO.

1 54758

2 48106

7

8

9

5

6

3

4

10

11

12

13

14

73146

48104

71934

80653

80634

21384

47846

47823

72559

31768

27592

27265

Snap Ring

Mounting Hub

Square Key

Screw

Bearing

Traction Cord Spring

Spring Cover

Flat Washer

Screw

Spring Mounting Screw

Stand Off

Screw

Power Supply Shield

Power Supply

10

DESCRIPTION

66

7

8

9

QTY

1

1

1

1

1

1

4

4

1

1

4

1

1

1

8 PARTS

8.7 SOLENOID AND CLAMP ASSEMBLIES

6

2

1


2

5

4

3

ITEM PART

NO.

1 48023

2

5

6

3

4

47851

48014

21384

47851

48097

Clamp Assembly

Screw

Solenoid Assembly

Flat Washer

Screw

Front Traction Cord Guide

DESCRIPTION

67

QTY

1

8

2

1

1

2

8 PARTS

8.8 LARGE DRIVEN GEAR AND SPOOL ASSEMBLY


1

2

3

8

7

6

9

7

8

9

5

6

3

4

ITEM PART

NO.

1 47997

2 48103

72017

47851

80158

47840

48104

71934

47839

Retaining Bar

Spool

Set Screw

Screw

Clamp Foot

Hub

Screw

Bearing

Large Driven Gear with Shaft Assembly

DESCRIPTION

68

5

4

3

QTY

4

1

1

1

1

2

2

1

1

9 SCHEMATICS


9.1 TRITON TRACTION UNIT SCHEMATICS

A. General Information

1. Due to the complex nature of the technology utilized by Chattanooga Group, the recommended

PCB troubleshooting techniques are to determine “Bad Board” and board replacement only. No PCB

component level troubleshooting is recommended, nor will information or parts be supplied by

Chattanooga Group. Any PCB component level troubleshooting performed will be at sole risk and

liability of the Service Technician performing such troubleshooting techniques.

2. Once a particular PCB has been determined as bad, replace the PCB. Use only Chattanooga

Group replacement parts and hardware. Refer to Section 8 Parts for replacement parts and assemblies.

69

9 SCHEMATICS

70

Control Board- 47801

1 of 3


9 SCHEMATICS

71

Control Board- 47801

2 of 3


9 SCHEMATICS

72

Control Board-47801

3 of 3


9 SCHEMATICS

73


Motor Control Board- 47803

1 of 2

9 SCHEMATICS

74


Motor Control Board- 47803

2 of 2

9 SCHEMATICS

75


Patient Interrupt Switch- 48056

1 of 1

9 SCHEMATICS

76

Serial Interface- 47022

1 of 1


9 SCHEMATICS

77

Smart Card- 47807

1 of 1


9 SCHEMATICS

78

sEMG Module- 48123

1 of 1


9 SCHEMATICS

79

Block Diagram

1 of 1


10 SPECIAL FIXTURES

80

Calibration Fixture

1 of 4



81


2 of 4



82


3 of 4



83


4 of 4


11 WARRANTY


Chattanooga Group (“Company”) warrants that the Triton Traction Unit (“Product”) is free of defects in material and workmanship. This warranty shall remain in effect for two years (24 months) from the date of original consumer purchase. If this Product fails to function during the two year warranty period due to a defect in material or workmanship, Company or the selling dealer will repair or replace this Product without charge within a period of thirty days from the date on which the Product is returned to the Company or the dealer.

All repairs to the Product must be performed by a service center authorized by the Company. Any modifications or repairs performed by unauthorized centers or groups will void this warranty.

The warranty period for accessories is 180 days. Accessories consist of Patient Interrupt Switch shipped with the unit.

To participate in warranty coverage, this Product’s warranty registration card (included with Product) must be filled out and returned to the Company by the original owner within ten business days of purchase.

This Warranty Does Not Cover:

• Replacement parts or labor furnished by anyone other than the Company, the selling dealer, or a certified

Company service agent.

• Defects or damage caused by labor furnished by someone other than Company, the selling dealer, or a certified Company service agent.

• Any malfunction or failure in the Product caused by product misuse, including, but not limited to, the failure to provide reasonable and necessary maintenance or any use that is inconsistent with the Product User

Manual.

COMPANY SHALL NOT BE LIABLE IN ANY EVENT FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

To obtain service from Company or the selling dealer under this warranty:

1. A written claim must be made within the warranty period to the Company or the selling dealer. Written claims

made to the Company should be sent to:

4717 Adams Road

Phone: USA: (800) 592-7329

Fax: (423) 875-5497

Canada: (800) 361-6661

Outside USA: +1 (423) 870-7200

Outside USA Fax: +1 (423) 870-2046

2. The Product must be returned to the Company or the selling dealer by the owner.

This warranty gives you specific legal rights and you may also have other rights which vary from state to state or location to location.

The Company does not authorize any person or representative to create for it any other obligation or liability in connection with the sale of the Product. Any representation or agreement not contained in the warranty shall be void and of no effect.

THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED,

INCLUDING ANY WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

84

© 2006 Encore Medical, L.P.

ISO 13485 Certifi ed

4717 Adams Road

P.O. Box 489

Hixson, TN 37343

U.S.A.

1-423-870-2281

1-800-592-7329

U.S.A.

1-800-361-6661

CANADA

+1-423-870-7200

OUTSIDE U.S.A

+1 423-870-2046

OUTSIDE U.S.A. FAX chattgroup.com

Medical Device Safety Service (MDSS)

Burckhardtstr. 1

D-30163 Hannover

Germany

Telephone: +49-5103-939430

48160A

0 4 1 3

Triton Traction Service Manual Domestic DTS Model

SERVICE MANUAL

International Model- 4749

International with sEMG Model- 4798

Domestic Model- 4739

Domestic with sEMG Model- 4778

Domestic DTS Model- 2841

Control Board- 47801

1 of 3

Control Board- 47801

2 of 3

Control Board-47801

3 of 3

Motor Control Board- 47803

1 of 2

Motor Control Board- 47803

2 of 2

Patient Interrupt Switch- 48056

1 of 1

Serial Interface- 47022

1 of 1

Smart Card- 47807

1 of 1

sEMG Module- 48123

1 of 1

Block Diagram

1 of 1

Calibration Fixture

1 of 4

Calibration Fixture

2 of 4

Calibration Fixture

3 of 4

Calibration Fixture

4 of 4

Related manuals

Chattanooga

Triton 4798

Fabrication Enterprises

00-4739

Fabrication Enterprises

00-4759

Chattanooga Group

OptiFlex S

3B SCIENTIFIC

W49812

Chattanooga Group

ERGOSTYLE FX 5822

Chattanooga Group

OptiFlex